Machining Performance Optimization for Electro Discharge Machining of Inconel 625: A Case Experimental Study

Abstract

An experimental investigation on assessing machining performance during Electro-Discharge Machining (EDM) of Inconel 625 has been attempted herein. Based on 5-factor-4-level L16 orthogonal array, experiments have been carried out by varying gap voltage, peak current, pulse-on time, duty factor and flushing pressure (each varied into four discrete levels) to examine machining performance characteristics like electrode wear ratio, radial overcut, roughness average, and surface crack density of EDMed end product obtained by utilizing different parameters settings as per design of experiment. An integrated optimization route combining satisfaction function approach and Taguchi’s philosophy has been proposed for simultaneous optimization of aforementioned multiple performance indices. Predicted optimal parameters setting has been verified by confirmatory tests. In addition to that, analysis of SEM micrographs has been carried out to investigate surface irregularities for EDMed Inconel 625 end products